1 AMS-02 Integration & Test Plans & Status Ken Bollweg/NASA John Heilig/JS Robert Becker/MIT 12 January, 2007 AMS JSC

2 Agenda AMS Assembly Area/Clean Room 867 STA & Flight Integration Hardware Status Pre-integration of STAs in the Flight USS prior to STA VC/CMR arrival Pre-integration of Detectors on the STA VC & Flight USS prior to Flight Cryomagnet arrival Integration discussion items & plans for resolutions Final Flight Integration Integration data delivery

3 AMS Assembly Area Clean Room 867 Everything in the AMS Assembly Area/Clean Room 867 needed to begin the STA integration will be ready no later than (NLT) February 2, Operation as a Clean Room (air conditioning, filters, sealed & positive pressure) will be ready in May, 2007 Rotation Assembly Stand (RAS) delivered, assembled, installed, and ready for use Scaffolding delivered, assembled, and ready for use

4 AMS Assembly Area Clean Room 867 Information provided in the Resource Requirements checklists has been used to order common use supplies and to estimate facility requirements Work area required – with & without crane access & special access Crate storage area, volume, and environment Tables & chairs Storage cabinets & open shelves Air bearing pallet requirements Cleaning fluids/supplies & vacuum cleaners Supply gases (Xe, He, CO2, N2, Compressed air, etc.) Fans for ventilation/cooling of hardware & personnel Power requirements ??? If you didn’t ask for it on the checklists, do NOT expect it to be provided!

5 Remov- able Ceiling Panels N Ceiling Panels are NOT Removable Airlock AMS Assembly Area Clean Room 867

6 STA VC integration with the STA Magnet (Cold Mass Replica - CMR) was completed in December at SM STA VC Arrived in Terni/INFN for Sine Sweep Tests on January 10th Test hardware was previously shipped to Terni and testing has been completed Ship STA VC to ESTEC for Acoustic Tests - March ’07 * Return to CERN for integration in USS – late March ’07 * * Depends on results of STA VC/CMR sine sweep & acoustic tests AMS STA Integration Hardware

7 Flight USS is complete and will arrive at CERN with the Primary Support Stand (PSS) and the Primary Lift Fixture (PLF) on January ~22-23, 2007 AMS Flight Integration Hardware Flight Vacuum Case is complete and will be shipped to SCL/SM when they have room in their facility to accommodate it (after Flight Cryomagnet tests are completed and the SFHe Tank is delivered and SFHe leak tested)

8 Pre-integration of STAs in the Flight USS Prior to STA VC Arrival STA Hardware Pre-integration in Flight USS On-line integration of the STA Crates/Radiators on the USS will begin the week of February 5, 2007– before the STA VC arrives This allows work to proceed even if the sine sweep & acoustic tests are delayed 10T crane installation will be delayed until after STA Pre- integration is complete at beginning of March If necessary, the USS/STAs in PSS will be moved away from crane installation There are ~3-4 weeks available in March to use the flight USS & STAs for fit checks, cable & plumbing runs, measurements, etc.

9 STA Hardware assembly in Flight USS (cont) Integration of all STAs in USS to be completed by mid-April ’07 * Even though the STA VC delivery to Terni slipped ~5 weeks and the RAS readiness at CERN slipped ~3 weeks, this is only ~2 weeks later than previously reported at AMS TIM on October 27, 2006 Ship USS with STAs to Munich/IABG in April ’07 * Static Tests Modal Tests Return USS with STAs to CERN in August ’07 * * Depends on results of STA VC/CMR sine sweep & acoustic tests and USS/STA modal & static tests Pre-integration of STAs in the Flight USS Prior to STA VC Arrival

10 Integration Discussion Items Interference between Flight VC/Magnet & Electronics Crates during Final Flight Installation Interference with installation access holes on LUSS after LTOF is installed ECAL Main Fixation Bolts & Shims TRD M-Structure Shear Pins & Eccentric bushings Schedules, Schedules, Schedules

Top Views Bottom Views

Temporarily remove mid- brackets and lower struts

Move Main Ram & Wake Radiators outward to allow installation of Flight VC & Magnet Temporarily Reattach Top Brackets to Upper USS

14 Interference between Flight VC/Magnet & Electronics Crates during Final Flight Installation R. Becker/MIT, J. Kastelic & P. Mott/JS, & R. Stafford-Allen/SM to determine how much room is required to clear the Flight VC/Magnet as well as how much room is available by Jan 29 th. Provide estimate of additional length required for lower inter-radiator cables to M. Capell & A. Lebedev Final cable routing must accommodate additional length Be sure there’s no interference with hardware mounted outboard of crate jigs during pre-integration activities Upper inter-radiator connections will be disconnected because the additional length will be too much additional weight C. Lauritzen/JS to determine if there is any problem on the USS if the brackets are temporarily re-attached at a wider position by Feb 5th M. Molina/CGS to determine if Radiator brackets are OK by Feb 5th Consider using blocks/spacers under the brackets and reattaching the lower struts K. Bollweg & J. Heilig will arrange trial test using STA Crates/radiators in late February

15 Interference with installation access holes on LUSS after LTOF is installed J. Kastelic to provide USS Interface info to G. Laurenti & F. Cadoux by Feb 16 th so four new handling brackets can be made G. Laurenti to produce new handling brackets by Sept 1st New handling brackets will use existing fasteners and swivel hoists F. Cadoux to provide extra long hold-down bolts to GSE

16 ECAL Main Fixation Bolts & Shims NASA will provide the ECAL Main Fixation Bolts The flight Shims have already been provided

17 TRD M-Structure Shear Pins & Eccentric Bushings for STA SS - Aachen SS or Al - Aachen SS Bolts, Nuts, & Washers - NASA SS – NASA? Aachen? SS - Aachen SS – NASA? Aachen? Al or SS - NASA USS (Al) - NASA TRD M Structure (Al) - Aachen

18 TRD M-Structure Shear Pins & Eccentric Bushings for Flight Ti - Aachen SS Bolts, Nuts, & Washers - NASA SS – NASA? Aachen? Ti - Aachen SS – NASA? Aachen? Al or SS - NASA USS (Al) - NASA TRD M Structure (Al) - Aachen

19 All the detector groups have continued to evaluate the pre- integration proposal and have agreed that it should proceed according to the schedules thoroughly discussed at this TIM Current estimate of Pre-integration start: August, 2007 Pre-integration finish: December, 2007 Optical fibers between ACC & VC for TAS will be installed Constantly monitor the Cryomagnet progress and decide how much more flight hardware to pre-integrate Current estimate of magnet delivery to CERN: February, 2008 Do as little de-integration as possible – just in time to remove the STA VC and install the Flight VC & Cryomagnet in the USS Pre-integration of Detectors on STA VC & USS prior to Cryomagnet Arrival

20 Consider removing the STA VC, Tracker, and ACC from the USS as an assembly so parallel work can continue during Flight VC/Magnet installation Use VC rotation fixture and wheels/brackets developed at SM This could shorten deintegration by 2-3 weeks; thus allowing combined cosmic ray testing to be extended Pre-integration of Detectors on STA VC & USS prior to Cryomagnet Arrival

21 All detectors must be integrated and functionally tested with the Flight VC and Cryomagnet at CERN by July, 2008 Beam tests at CERN (~1 month reserved) Thermal Vacuum Tests at ESTEC (~3 months reserved) EMI Tests at ESTEC (~1 month reserved) Delivery to KSC in December, 2008 Final integration of Detectors on Flight VC & USS after Cryomagnet Arrival

AMS Integration Data Delivery

What we have… sort of.

Where we must be by December 2008 at KSC...